INTRODUCTION AND INSTRUCTIONS

Thank you very much for participating in the extra data collection efforts in support of DOE's neg

for pumps. In the following tabs you will find requests for a variety of information related to circu

will support our efforts to directly address the inquiries of the pumps rulemaking working group.

We will treat this data as confidential under the terms of the NDAs on file with Navigant and LBN

Timeline: The deadline for submission is Friday, January 17, end of day.

We realize this is a very short timeline, but we are hoping to be able to aggregate da

next stakeholder meeting on January 30 in order to help stakeholders negotiate rule

Priority: Ideally we would like you to answer all of the questions as accurately as possible. Bu

realistically we understand that accurate estimates may not be available within the r

turnaround. That said, please address all questions as best you can, but give priority 

highlighted in green and ensure that you can provide accurate responses to those q

Format: If you don't feel you can provide the data in the format we have suggested here, ple

to discuss alternative formats.

Clarity: If you have any questions at all regarding the clarity or intent of a survey question, p

hesitate to call Navigant. Contact info is:

Daniel Weintraub

Navigant

Email: daniel.weintraub@navigant.com

Office: 781-270-8397

Cell: 516-849-6100 
support of DOE's negotiated rulemaking 

mation related to circulators. This data 

aking working group.

th Navigant and LBNL.

 able to aggregate data in advance of the 

olders negotiate rulemaking scope.

rately as possible. But 

available within the requested one-week 

but give priority to the tabs 

responses to those questions.

e suggested here, please contact us 

 a survey question, please do not 
Question 1, Table 1

List all Circulators 1/25 to < 3 HP 2013 2012 2011 2013 2012 2011

Model Name Housing 

Material

Rotor Type: 

[Wet/Dry]

Motor Type: 

[ECM/AC]

Speeds and Controls

[See dropdown and definitions 

below]

Circulator 

Classification*

Nameplate 

HP

Max Rated 

Electrical Power 

Draw to Motor 

(Watts)

Rated Electrical 

Power Draw at 

Middle Selectable 

Speed or Median of 

Speed Range 

(Watts)

Rated Electrical 

Power Draw at 

Minimum 

Selectable Speed

(Watts)

Example: ABC 1001 Cast Iron Wet AC Single Speed - No Control CP1 1/25 85 77 60

$0.00 $0.00 $0.00 0 0 0

Please add lines as necessary

Survey on Shipments: 1/25 to < 3 HP Pumps

Net Sales $ Volume

NOTE: This represents total revenues from sales to United States distributors 

or any other direct United States customers, including OEM products for use 

in the USA.

 Unit Volume

NOTE: This represents total revenues from sales to United States distributors 

or any other direct United States customers, including OEM products for use 

in the USA.

For Multi-Speed - Manual

Circulators Only
New Product Introductions

2. The survey on the first tab only considers shipments up to December 31, 2013. Please provide any relevant 

information on energy efficient circulators that are planned for introduction in the next two years. Please feel 

free to attach separate files, or provide data in whatever format is most convenient.

3. How do you expect the market penetration of high efficiency circulators to change over the next 5 years?

- Please discuss this only in terms of your own company's market share. 

- Please provide estimates of predicted trends for ECM sales, as a percentage of your total sales, if available. 
Survey on Load Profiles

The following questions are to help better understand representative load profiles for the US circulator 

market. Such profiles will be used to aid in the calculation of annual energy consumption and potential 

4. Constant Speed Circulators

4a. For Heating Applications: In the United States, how many hours per year do you believe the average 

constant speed circulator runs?

- Please provide your answer in terms of days/year of system operation and hours/day of system and or zone 

operation.

4b. For Potable Water Applications: In the United States, how many hours per year do you believe the average 

constant speed circulator runs?

- Please provide your answer in terms of days/year of system operation and hours/day of system and or zone 

operation. 

4c. While operating at a point lower than max flow, do you believe a standard AC single speed circulator draws 

significantly lower power (watts) than max rated power draw (watts)? 

If so, what percent of rated motor power draw do you estimate the average circulator runs at? 

This question is based on the understanding that the intersection of the system curve and pump curve defines 

the actual electrical power draw (watts).

5. Multi-Speed - Manual User-Selected Control

5a. For Multi-Speed - Manual circulators, what do you estimate as the average speed setting that your products 

are run at? Please provide a weighted average between 1 and 3, using the following parameters:

Max Speed = 3.0

Mid Speed = 2.0

Min Speed = 1.0

For Example:

Pumps run at max speed 90% of the time, mid speed 7% of the time, and min speed 3% of the time.

(90% x 3.0)+(7% x 2.0)+(3% x 1.0) = 2.9

Please do not include time spend at zero speed or off.

6. Variable Speed Circulators
6a. Given the differences between the European and North American circulator markets and applications, do 

you feel that the EU Lot 11 load profile (Blauer Engel) for circulators applies to the US market? Please explain 

Blauer Engel / EU Lot 11 Load Profile for System operation:

6% time at design load (max) 

15% time at 75% design flow

35% time at 50% design flow

44% time at 25% design flow

6b. If no, please elaborate on a load profile that might best represent the US market in calculations used to 

estimate national energy usage and potential energy savings.

 If possible, please differentiate between Heating and Potable Water applications.

6c. Given your variable speed load profile of choice, Blauer Engel or otherwise, do you believe that variable 

speed circulators run more hours per year than a single speed circulator?

(This question is based on the premise that a modulated variable speed system may run more hours at lower 
7b. Larger than 100 watts

Survey on ECM Availability

Please answer for the follow two HP groupings:

Do you have sufficient manufacturing resources* or sufficient external supply** to meet your company's full scale*** E

Do you envision there being sufficient manufacturing resources and/or external supply by 2020?

*Manufacturing resources include but are not limited to: production infrastructure, trained personnel, and manufacturing components (including m

**External supply refers to complete ECMs that meet your specs, and are available to be purchased and shipped to your factory.

*** Full scale means that all of your current circulator shipment would require ECM.

The following questions are to help better characterize the availability of ECM suitable for use in the circulator mark

7. Suppose that a potential DOE regulation effectively required ECM on all circulators (CP1, CP2 and CP3).

7a. 100 watts and smaller
ur company's full scale*** ECM production needs by the start of 2015?

acturing components (including magnets). 

o your factory.

 use in the circulator market
Table 8a

Column 1 Column 2 Column 3 Column 4 Column 5

Nameplate HP

[1/25 to 3 HP]

AC MOTOR

Max Rated Electrical 

Power Draw (Watts)

Single Speed AC 

Motor Cost ($)

Three Speed AC 

Motor Cost ($)

[If Applicable]

Current Pricing

ECM Cost ($) 

[Replacement for the 

motor in Column 2]

Table 8b

Column 1 Column 2 Column 3 Column 4 Column 5

8. In the tables below, please provide comparative manufacturing or purchasing costs for ECM vs. traditional circulator AC m

Please provide the ECM costs under two assumptions: 

- Column 5: Current unit motor cost -- This is the 2014 per-unit cost to either manufacture or purchase from an outside supp

- Column 6: Economies of scale -- This is an estimate of the 2020 per-unit cost to either manufacture or purchase from an ou

AC motors.

NOTES:

- AC Motor Cost for CP1 includes cost both of the stator and the rotor.

- Cost should represent either the actual/estimated cost to manufacture internally or purchase from an outside supplier.

 - In the space to the right of the table please comment on which motor types and sizes you currently make/buy and w

- ECM costs should include the cost of the integrated motor controller and the additional logic controller.

 - Assume that all products will be sold with logic and "smart controls." 

- Because ECM do not come in "standardized" increments and can cover a larger hydraulic range than AC motors, please pro

specify this ECM wattage in Column 7.

CP1 ONLY

CP2 ONLY

Survey on ECM Cost

The following questions are to help better characterize the costs of ECM suitable for use in the circulator market
Nameplate HP

[1/25 to 3 HP]

AC MOTOR

Max Rated Electrical 

Power Draw (Watts)

Single Speed AC 

Motor Cost ($)

Three Speed AC 

Motor Cost ($)

[If Applicable]

Current Pricing

ECM Cost ($) 

[Replacement for the 

motor in Column 2]

Table 8c

Column 1 Column 2 Column 3 Column 4 Column 5

Nameplate HP

[1/25 to 3 HP]

AC MOTOR

Max Rated Electrical 

Power Draw (Watts)

Single Speed AC 

Motor Cost ($)

Three Speed AC 

Motor Cost ($)

[If Applicable]

Current Pricing

ECM Cost ($) 

[Replacement for the 

motor in Column 2]

CP3 ONLY
Make vs. Buy

Column 6 Column 7

2020 Economies of 

Scale

ECM Cost ($)

[Replacement for the 

motor in Column 2]

REPLACEMENT ECM

Max Rated Electrical 

Power Draw (Watts)

Make vs. Buy

Column 6 Column 7

aditional circulator AC motors. Three tables have been provided, corresponding to CP1, CP2, and CP3 product types. 

ase from an outside supplier.

 or purchase from an outside supplier, under the assumption that ECMs are to be sold at volumes similar to the current 

 an outside supplier.

rrently make/buy and which sizes and types plan to make/buy in 2020.

n AC motors, please provide the cost of a motor that would replace the AC motor size specified in column 2. Please 

Please comment below on sizes/types you currently 

make/buy and which sizes and types plan to make/buy in 

2020.

e circulator market
2020 Economies of 

Scale

ECM Cost ($)

[Replacement for the 

motor in Column 2]

REPLACEMENT ECM

Max Rated Electrical 

Power Draw (Watts)

Make vs. Buy

Column 6 Column 7

2020 Economies of 

Scale

ECM Cost ($)

[Replacement for the 

motor in Column 2]

REPLACEMENT ECM

Max Rated Electrical 

Power Draw (Watts)

Please comment below on sizes/types you currently 

make/buy and which sizes and types plan to make/buy in 

2020.

Please comment below on sizes/types you currently 

make/buy and which sizes and types plan to make/buy in 

2020.
$0.00

$0.00

$0.00

$0.00

10. Please provide details on what product types or models would be discontinued, rather than redesigned.

Sub Totals

Marketing

Sub Totals

Pump Size: 1 HP

[These costs should be representative of larger, lower volume 

circulators]

Pattern, Tooling

Number of ECM Families ≤ 1/4 HP to be developed

TOTAL REDESIGN COST TO MANUFACTURER

Number of ECM Families > 1/4 HP to be developed

TOTAL REDESIGN COST TO MANUFACTURER

Marketing

Survey on the Cost of Circulator Design

9. In the tables below, please provide quantitative detail on the costs required to redesign from an AC motor driven circulato

circulator with the most efficient available hydraulic design. We are interested in two specific sizes ranges, 1/4 HP and 1 HP.

Please note the following:

- Assume you are designing for introduction by year 2020.

- Assume that your tooling costs must satisfy production volumes equal to your current AC motor sales.

- We are interested in the cost to design one FAMILY of circulators.

- FAMILY is defined as a group of similar sized circulators that would be designed together in one effort, under one budget.

- Because each manufacturer's functional definition of FAMILY may be different, we ask that you specify the number of FAMI

designed if ECM were to be required on all circulators.

 - This number may be lower than your current number of AC motor families.

- Multiplying number of families by your per-family design cost should give us a rough indication of the total cost of redesign 

- We understand that not all current models would be carried over to ECM. If you currently manufacture a certain class of cir

plan to redesign it for ECM, please leave column blank and provide details in question 10 below. 

- Please use the legend provided to the right to define each term. 

Redesign, Prototype & Initial Test

Pump Size: 1/4 HP

[These costs should be representative of smaller, higher volume 

circulators] CP1

Working Capital

Final Testing

Pattern, Tooling

Redesign Cost for one Circulator FAM

Redesign Cost for one Circulator FAM

Table 9a

Table 9b

Redesign, Prototype & Initial Test

CP1

Final Testing

Working Capital
12b. We understand that some product families may already be redesigned, but are not prepared for high volume manufact

the aggregate additional tooling and infrastructure costs that you believe are necessary to bring these product families up to 

Only specify unique costs not covered in Question 9. 

How many product families are included in these costs?

13. How would you expect to recover these expenses?

- Margin increases to all product offerings (circs and larger pumps)

- Margin increases to all circulator offerings only

- Margin increases to redesigned products only

- No Margin increases -- absorb costs internally

- Other (please elaborate)

11. Do your costs represent internal manufacturing or external sourcing of ECM?

12. Tooling Costs --

12a. We understand that production infrastructure may be shared across multiple circulator product families. 

If multiple product families were to require redesign, can we directly scale up your tooling costs, or do these costs cover mult
$0.00 $0.00

$0.00 $0.00

$0.00 $0.00

$0.00 $0.00

d, rather than redesigned.

redesign from an AC motor driven circulator to an ECM driven 

two specific sizes ranges, 1/4 HP and 1 HP.

rrent AC motor sales.

ogether in one effort, under one budget.

we ask that you specify the number of FAMILIES that would be 

ugh indication of the total cost of redesign for your company.

 currently manufacture a certain class of circulator, but would not 

tion 10 below. 

CP2 CP3

Redesign Cost for one Circulator FAMILY

Redesign Cost for one Circulator FAMILY

CP2 CP3
re not prepared for high volume manufacturing. Please estimate 

essary to bring these product families up to high volume by 2020. 

e circulator product families. 

r tooling costs, or do these costs cover multiple product families?
LEGEND

Design Process Factor Descriptions

Design Costs:

Hydraulic Design, Mechanical Design, Electrical and Motor Design, Controller 

Design, Simulation, Prototype Development, Prototype Tooling, Initial Testing

Pattern & Tooling Costs:

Supplier Development, Patterns, Tooling (Machine Fixtures, Assembly Fixtures, 

Test Fixtures). Machine Programming, Quality Inspection (Parts, Tooling), 

New Process Development (Casting and/or Machine Processes), New Machine 

Tools, Retraining.

Testing:

Performance (All Speeds), Hydrostatic, Certification Testing, Field Beta Testing

Production Documentation, Training, etc.

Working Capital:

Cost of money to finance upgrades, Inventory (Cost, Rework Transition, 

Inventory for legacy support.)

Marketing:

Literature, Data Sheets, Curves, Pump Selection Tools, Sales Training, 

Compliance Documentation, etc.
Survey on Circulator Testing Costs

The following questions are to help better characterize the capital and per-unit costs associated with 

testing circulators, in the presence of an energy conservation standard.

14. Do you currently use ISO9906 as the test method to develop published circulator performance data for end 

users? If not, please describe how your methods differ, or attach any relevant performance verification testing 

methodology.

15. Assuming a certified test procedure requires data such as head, flow, power consumption, and line to water 

efficiency at various load profiles and various system curves, please describe the additional one time investment 

costs (conversion costs) needed to setup facilities to adequately test circulators for certification. 

- Please assume accuracy limits similar to those set forth in the EU Lot 11 circulators test procedure. Relevant 

accuracy parameters are listed in the cell below.

- Please consider the aggregate cost to establish facilities capable of testing all circulator HP ranges for CP1, CP2, 

CP3.

- Please account only for costs needed to go beyond your current testing capabilities. 

- Please provide an estimated dollar value as well as a description of what these costs represent.

Relevant Accuracy Parameters:

- Ambient temperature held to +/- 5oC

- Static system pressure of 2 Bar. (Tolerance of +.5bar/-0bar)

- Nominal motor input voltage held within ±1% of nominal

- For tolerance on Q/H load curve points -- Maximum permissible distance between H100% and published curve:

 For motors ≤ 100 W: +/-20%

 For motors > 100 W: +/-10%

- Although there are more parameters, please consider these at this time.

15b. Have the costs in 15a been included in your cost of Cost of Product Development numbers specified in the 

previous tab?

16. What is the estimated cost to test and certify each model to a DOE standard?

- For the purposes of this analysis, a model is defined as a unique combination of electrical and hydraulic designs. 

For example, identical pumps with different flange fittings need not be tested separately.

- For certification, the model only needs to be tested once. Once certified, individual production units need not 

be tested.

17. How many models do you anticipate having to certify?
18. If you feel that the accuracy limits and equipment requirements of the EU Lot 11 test procedure is 

inappropriate for the US market, please provide details on a test procedure you support. In addition please